SERVICE

MANUAL
Models

PTG109, PKV101, PKX201H,

PKX201, PKX301,
PKX201T, PKX301T,
PKX201ST, PKX301ST
Step by Step Procedure for Removal or
Repair of Pump Components on Subaru Robin
Pumps
(This Includes Mechanical Seal Replacement
and Proper Shimming)

PUB-PS001
Rev. 09/05

GROUP INDEX
Group Name ...................................................................................................................... Page

PTG109 .....................................................................................................................................4

PKV101 ...................................................................................................................................16

PKX201, PKX301 - Centrifugal................................................................................................28

PKX201T, PKX301T - Trash ....................................................................................................42

PKX201ST, PKX301ST - Semi-Trash ......................................................................................60

PKX201H - High Pressure .......................................................................................................74

PTG109

Service
1. Remove the four outer pump housing bolts.

2. Remove the outer pump housing cover.

3. Remove the volute from the pump back plate .

4. Remove the outer pump housing to pump back plate

gasket. This will be a good time to check the gasket for
cracks, tears, and overall condition. Replace if necessary.

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PTG109

Service
9. For engine service work, or seal replacement, the
pump back plate will need to be removed. Loosen and
remove the four bolts with a allen socket or wrench.

10. Pull the pump back plate away from the engine.

11. The engine in now separated from the pump components for service.

12. To remove the stationary seal from the back plate it will
be necessary to turn the pump back plate face down
on the workbench. Take a 3/4 inch socket and position
it into the cavity behind the seal.

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PTG109

Service
17. Check the condition of the volute seal for cracks, worn
spots, and overall condition. Replace with new if
necessary.

18. Check the condition of the volute. If cracked chipped or

bent, it must be replaced.

19. When reinstalling the back plate to the engine make

sure the weep hole faces downward. Weep hole must
be free from debris.

20. When replacing with a new seal, silicone compound

is not needed. However, if original seal is removed and
replaced back into pump back plate, then a small
amount of silicone sealant will help seal it. Place a thin
bead of sealant around the metal part of the seal.

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PTG109

Service
25. After the seal has been installed place the pump back
plate over the crankshaft and loosely install one of the
bolts to hold it in position.

26. A small amount of thread locker compound should be

used on the tip of the bolts. This thread locker should
be a service replaceable type such as Permatex Blue
or Purple.

27. After placing the bolts into the back plate, tighten the
bolts snugly.
Proper torque clearance should be 2.2 to 3.7 ft. lbs

28. If the pump came installed with shim(s) they must be

replaced with same number that came off. If none
were installed originally, then do no put a new shim on
unless gap between impeller and volute is wider than
the tolerance allows.

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PTG109

Service
33. Tighten the impeller with a rubber mallet by hitting on
one of blades in a clockwise position until tight.

34. The casting marks on the pump back plate indicate

where the volute must be placed. Make sure that the
volute is placed correctly inside these marks.

35. After installing the rubber gasket on the face of the

volute, place the volute on the pump back plate. Tip
the unit back slightly to hold it in position.

36. Make sure there is enough clearance between the

volute and impeller, use a feeler gauge to check the
gap. While holding the volute tightly against the pump
back plate, insert different size feeler gauge blades
until the correct reading is obtained.
The recommended clearance is 0.024 to 0.039
thousands of an inch.

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PTG109

Service
41. This picture shows the correct placement of the gasket
to the intake nozzle housing.

42. Tighten the three outer bolts, making sure not to over
tighten. The gasket will be distorted and squeezed
when overtightening these bolts.
The recommend tightenting torque is 3.3 to 4.8 ft. lbs.

43. Pull the engine over by the start pull cord, making sure
nothing is binding in the pump.

44. After adding priming water and fuel, start the unit and
check with test vacuum plate to make sure there are
no vacuum leaks.
The recommended vacuum reading at sea level should
be 25 lbs of vacuum.

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PKV101

Service
1. Drain any water from the reservoir and remove the 4
bolts that hold the outer casing to the pump back plate.

2. Pull the cover away from the back plate, keeping

tipped back.

3. Note position of volute slot and outer case locating tab.

This tab and slot holds the volute in the correct position. This must be positioned correctly during reassembly.

4. Remove volute from the outer pump housing, checking for cracks or any other damage that may have occurred.

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PKV101

Service
9. Inspect the impeller for cracks in the casting or chips in
the blades.

10. Remove the spring and set aside.

11. The shim(s) should be located over the crankshaft in

this position.

12. Remove the shim(s). Count the number taken off and
make sure to replace the same amount when reinstalling.

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PKV101

Service
17. Carefully pry the stationary seal outward, using two
screwdrivers if necessary. Note: if the seal is stuck in
casing it may become necessary to squirt a small
amount of liquid soap and water on sealing surface to
loosen seal . It also may become necessary to remove the back plate to push the seal out when
prying from the front does not work.

18. Inspect both halfs of the seals for imperfections and

replace as necessary.

19. If it becomes necessary to remove the frame and back

plate from the engine for engine service remove the
two bolts that hold the frame to the bottom of
back plate.

20. Remove the four bolts that hold the back plate to the
engine.

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PKV101

Service
25. Torque the 4 bolts to the specified value.
The recommended torque is 7-9 ft. lbs.

26. Position the frame under the back plate for reinstallation

27. Install and tighten the two bolts that hold the frame to
the back plate.

28. Squirt a small amount of liquid detergent on the seal

and crankshaft before trying to reinstall. The detergent
acts as a libricant for the rubber seal.

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PKV101

Service
33. Re-install the shim(s) making sure you replaced the
same number that came installed with the pump. If a
new component such as a impeller or volute was
installed, refer to the section on proper shimming.

34. Screw and snug the impeller hand tight on the crank
shaft, making sure it is flush with the back plate.
Note:

If shims are not properly installed onto crankshaft,

the impeller will not fit flush to backing plate. If this
condition occures, remove impeller and push the
shims onto crankshaft further, making sure the
sims are not bent out of shape.

35. To inure the impeller is installed correctly, place the volute against the back plate. While holding the volute
tight against the back plate with one hand, check
the clearance between the volute and impeller with a
feeler gauge. If the clearance is larger than 0.040
thousands of an inch, then another shim must be
added.
The recommended clearance is 0.020 to 0.040 thou
sands of an inch.

36. If shims need to be added or subtracted then re

move the volute and impeller, taking note of how many
shims were added or subtracted. Re-install impeller
and check again. After proper clearance is
obtained install impeller once again.

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PKV101

Service
41. Should it become necessary to remove the inlet nozzle
and gasket, follow these steps. Remove the three bolts
that hold the inlet nozzle to the outer pump case.

42. Inspect the check valve gasket, noting that there is a

correct way to install it.

43. Picture show the correct installation of the check valve

gasket on the inlet nozzle.
When reinstalling inlet nozzle it is important not to over
tighten.
The correct torque value is 2 to 3 ft lbs.

44. The picture shows the correct position of the gasket

tab facing upwards.

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Centrifugal Pumps - PKX

Service
1. Drain water from the reservoir and remove the 4 bolts
that hold the outer casing to the pump back plate.

2. Remove outer casing and volute as an assembly. Tip

backwards not allowing the volute to drop out of the
casing.

3. Note the locating slot that is cast into the volute. This
must align with the notch cast into the outer casing
when re-assembling.

4. Tip the outer casing on its back and pull out the volute.
If the O-ring, on the back side of the volute causes the
volute to stick when trying to remove, use two hands to
lift out the volute, while holding the outer casing

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Centrifugal Pumps - PKX

Service
9. Inspect the impeller for defects.

10. Carefully remove the spring from the crankshaft. It can

be replaced in either direction.

11. Remove the shim(s) from the crankshaft. Count the

number that is used and replace with the same
amount. Should the impeller or volute be replaced
with new, it will become necessary to re-shim according the re-shimming guide located in service manual

12. If the shim(s) get stuck inside the impeller. Carefully

pry the shim(s) out with a small screwdriver. If
shim(s) get bent or are flattened beyond use, replace
with new one(s).

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Centrifugal Pumps - PKX

Service
17. Use a small screwdriver to pry between the ceramic
seal and the black rubber seal that holds it in place.

18. If the seal seems to be stuck, squirt some liquid soap

on the seal .This will loosen it from the black outer
rubber seal. Using one or two screwdrivers, pry the
seal outward. It may become necessary to remove the
pump backplate when the seal is stuck . See step 22
for removal of backplate.

19. This is what the seal will look like when removed.

20. Make sure never to use the back side of a seal when
reinstalling. The back side of the seal will usually have
some colored marks indicating it is the wrong way.

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Centrifugal Pumps - PKX

Service
25. When reassembling the back plate to the engine make
sure the weep hole is facing towards the bottom of
frame. The weep hole is to prevent water from entering
the engine should a mechanical seal fail.

26. Install the pump back plate onto the engine. Install with
one bolt to hold its position.

27. Place a small amount of thread lock sealer on the tip

of the bolts before reinstallation. This will prevent the
bolts from loosening.
Note:

Only use Allen head bolts and special sealing

washers. Washers should fit snug around the bolt.
Inspect for cracks in the sealing surface. Replace
with new if needed. Note: Threadlocker Blue
from Permatex is recommended. It is medium
strength and service removable.

28. The four bolts should be tightened snugly by hand.

Tighten diagonally to ensure even installation.

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Centrifugal Pumps - PKX

Service
33. Re-install the shim(s) using the same number as
was taken off. If new components such
as impeller or volute was used, it may become
necessary to re-shim with new shims for proper
clearance.

34. Hand tighten the impeller onto the crankshaft. Make

sure it is threaded on all they way. If the impeller is
not threaded to the full extend, the impeller face could
strike against the inside of the volute.

35. To make sure the impeller is installed correctly, hold

the volute against the back plate and check
the clearance with a feeler gauge. If the clearance is
larger than 0.040 thousands of an inch then another
shim must be added.
If the clearance is 0.020 or less and the pump grinds
and turns over hard, it is possible that a shim needs to
be removed.

36. Re-tighten the impeller with a hard rubber mallet, hitting the blades in a clockwise position. It should be
tight enough that you should not be able to turn it
loose by hand.

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Centrifugal Pumps - PKX

Service
43. Once the case is torqued down, pull the recoil starter
to check that pump and engine turn over freely. If OK,
then re-fill with prime water. Next check the engine oil
and start the engine. Apply vacuum pressure plate tester per service manual, and check for leaks.

44. If it becomes necessary to remove the discharge nozzle, the following procedure is recommended. Loosen
and remove the 4 bolts that hold the nozzle housing to
the outer casing.

45. Remove the discharge nozzle and inspect the gasket

and nozzle for cracks.

46. When replacing the gasket, make sure the gasket is

flat and not kinked. The gasket does not have a specified side for placing on the pump housing.

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Centrifugal Pumps - PKX

Service
51. This picture shows correct way to install the gasket.
Make sure the gasket is flat against the outer housing
when reinstalling cover. Align holes and thread the
three bolts into the nozzle and cover.

52. After reinstalling bolts, torque to the specified torque

value.
Note:

The gasket tab pointing upward showing correct

placement of gasket.
Torque to:
PKX201- 3 to 5 ft lbs.
PKX301-5 to 6 ft lbs.

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Trash Pumps - PKX

Service
1. Drain any water from the reservoir by loosening
the drain plug. Loosen the 4 knobs that hold the
outer pump housing to the back plate of the pump.
Use the special wrench provided with pump.

2. Push the 4 knobs to the side and remove the outer

pump housing from the pump back plate.

3. Inspect the volute and outer case for cracks and

bent castings. Also inspect wear plate any uneven
wear marks. For removal of volute and wear plate
from outer pump housing see steps 34 to 48 .

4. Remove plug on back plate housing for access

to impeller. Use a soft rod such as aluminum or
brass, and a hammer to loosen the impeller. Hit
counter-clockwise until loose.

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Trash Pumps - PKX

Service
9. Turn the impeller over and remove the rotating part of
the mechanical seal with a small screwdriver. Pry on
the bottom side and lift upward until removed from impeller.

10. There is a wrong side to the rotating seal. The white

or colored marks will face inward (or towards the inlet
nozzle side of the pump).

11. Sometimes it helps to put a little dish washing soap on

shaft to help remove seal. This prevents the sealing lip
from possibly tearing when removing.

12. Using two screwdrivers, remove the seal by prying

side to side until it is free. It may become necessary
to remove pump back plate to remove seal. If this
becomes the case then follow the directions in the following steps.

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Trash Pumps - PKX

Service
17. Lift the engine and back plate high enough to clear the
bolts from the frame mounts.

18. Pull the back plate housing from the engine. It may be
come necessary to tap of the back plate slightly with a
rubber mallet.

19. Should it become necessary to remove the engine for

service, then remove the two bolts that hold it to the
engine vibration mounts.

20. When replacing back plate on engine not the weep

hole on the backside of pump back plate housing.
The weep hole must not be blocked with dirt or other
obstruction. This weep hole prevents water from entering engine should a mechanical seal fail will pumping water.

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Trash Pumps - PKX

Service
25. After the back plate has been tightened, replace the
two bolts that hold the pump housing to the frame.

26 When replacing the mechanical seal. Putting some

liquid detergent on the seal and crankshaft will ease
installation.

27. Push the seal into place. Using two thumbs will also
make it easier. If the pump back plate was removed
it will be easier to install the seal before mounting the
back plate to the engine.

28. Replace the correct amount of shim(s). As noted

earlier it will be necessary to replace with the
same amount that was taken off.

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Trash Pumps - PKX

Service
33. To insure the impeller is tight. Hit on one of the bladed
in a clockwise position till good resistance is felt.

34. Should it become necessary to remove the volute from

front pump housing or replace the wear plate, follow
the next steps in removing and replacing.
Loosen the 3 bolts that hold the volute to the front
pump housing. These are Allen head bolts.

35. After the bolts have been removed, tap with a rubber
mallet to free the volute from the housing.

36. Carefully remove the volute from the housing by

pulling up.

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Trash Pumps - PKX

Service
41. This is what a new wear plate will look like. Compare it
to the one that was taken out.

42. Install the wear plate in the reverse order that is was
taken out.

43. Apply a light or medium duty thread locker to the wear

plate bolts before tightening. This should be a service
replaceable thread locker as mentioned ealier.

44. Tighten the three bolts that hold the wear plate to the
volute.

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Trash Pumps - PKX

Service
49. Install on back plate and loosely tighten the four knobs
making sure the O-ring is seated correctly.

50. Tighten the four knobs with the special tool that is
provided with the pump. Tighten very snugly.

51. Should it become necessary to remove the discharge

nozzle then loosen the four bolts that hold it to the
pump housing.

52. Lift the discharge nozzle off the housing watching the
position of the gasket. Check for cracks, tears or
improper fit.

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Trash Pumps - PKX

Service
57. Check the gasket for tears, cracks, or twists. Replace
if necessary.

58. Install the four bolts that hold the top cover to the
pump housing and torque to specified value of 16 to
20 ft. lbs.

59. Should it become necessary to remove the intake

nozzle for service then loosen the four bolts that hold it
to the pump housing.

60. Lift the intake nozzle away from the pump housing
noting the position of the gasket.

- 57 -

Semi Trash Pumps - PKX

Service
1. Drain the water from the reservoir and remove the 4
bolts that hold the outer casing to the pump back
plate.

2. Remove outer casing and volute as an assembly.

Keep tilted backwards so not to allow the volute
to fall out.

3. Note the slot that is cast into the volute. This must
align with the notch cast into the outer casing
when re-assembling.

4. Tip the outer casing on its back and pull the volute
from the outer casing. If the volute seems to be
stuck, (due to the O-ring sticking) then use two hands
while holding the outer casing with another person or
vise.

- 61 -

Semi Trash Pumps - PKX

Service
9. Inspect the impeller for defects.

10. Inspect the rotating part of the seal for cracks, chips
and worn face.

11. It many happen that the shim(s) get stuck inside the
impeller. When this condition occurs, carefully pry the
shim(s) out with a small screwdriver. If the shims(s) get
bent or are flattened beyond use, replace with new
one(s).

12. Place a small screwdriver under the seal and pry

outward. Placing some liquid (water or detergent) on
the seal might help in removing it if it appears to stick
to the metal.

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Semi Trash Pumps - PKX

Service
17. Slide the seal over the crankshaft.

18. After removing from the back plate, inspect the

surfaces closely. No cracks, chips or eneven wear
should show. If pump was run without water, the
surface of the seals will have a worn and burnt
appearance.

19. This is a good time to check the condition fo the

O-ring that seals the outer pump housing to the back
plate. Check for nicks, cracks, and replace with new
part if necessary.

20. If it becomes necessary to remove the back plate for

servicing the engine, use an allen wrench to remove
the 4 bolts that attach it to the engine

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Semi Trash Pumps - PKX

Service
25. When reinstalling the smaller adapter plate, make sure
the weep hole faces downward. The weep hole is to
prevent water from entering the engine should the seal
wear out.

26. The next step after placing the small adapter plate on
the engine is to mount the large adapter plate. Note:
the weep hole position as well, keeping it pointing
downward. Use one bolt to hold on temporarily.

27. Place a small amount of thread locking compound on

the tip of the mounting bolts when reinstalling. Note:
make sure to replace with special supplied bolts and
washer attached. These are special bolts that are
used for sealing pump to engine.

28. Tighten snuggly with hex head (allen wrench)

watching that the adapter plate align correctly with the
back plate.

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Semi Trash Pumps - PKX

Service
33. Pour a little liquid detergent on the backside of the
impeller before trying to install the rotating seal.

34. Push seal into cavity with one or two thumbs making
sure the seal is seated correctly.

35. Reinstall the impeller and hand tighten on the crank

shaft. Make sure it is threaded on all the way. If
impeller is not threaded on the full depth, the impeller
face could strike against the inside of the volute.

36. To make sure the impeller is installed correctly hold

the volute against the backplate and check the
clearance with a feeler guage. If the clearance is
larger that 0.040 in., then another shim must be
added. If there is less than 0.020 in of clearance
between the volute and impeller, then it is possible a
shim would need to be removed.
Note: make sure impeller is threaded tightly
against backing plate.

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Semi Trash Pumps - PKX

Service
41. Tighten and torque the four bolts to a minimum torque
of 200kg/cm.

42. Once the case is torqued down, pull the recoil starter
to check that pump and engine turn over freely. If OK,
then re-fill with prime water. Next check the engine oil
and start the engine. Apply vacuum pressure plate
tester per service manual and check for leaks.

43. If it becomes necessary to remove the discharge

nozzle, the following procedure is recommended.
Loosen and remove the 4 bolts that hold the nozzle
housing to the outer casing.

44. Remove the discharge nozzle and inspect the gasket

and nozzle for cracks.

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Semi Trash Pumps - PKX

Service
49. There is a correct way, and a wrong to install the inlet
gasket. Make sure that the gasket does not have
casting marks facing outward.

50. This picture shows correct way to install gasket. Make

sure gasket is flat against the outer housing when
reinstalling cover. Align holes and thread the three
bolts into the nozzle and cover.

51. After reinstalling bolts, torque to the specified torque

value. Note: the gasket tab that sticks upward showing
correct placement of gasket.

52. Pull the engine over with rope start to make sure
there is no binding of pump components. Then fill
with gas, oil, and prime water. Place vacuum tester
over intake opening and check inches of vacuum.
The needle should rise to 20 to 25 inches of
vacuum within a few seconds. If not, check for volute
to impeller clearance or gasket in pump components
that might not be seated correctly.

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High Pressure Pumps - PKX

Service
1. Drain water from the reservoir and remove the 4 bolts
that hold the outer casing to the pump back plate.

2. Remove outer casing and volute as an assembly. Tip

backwards not allowing the volute to drop out of the
casing.

3. Correct voulte placement is shown in picture.

Discharge chute is pointing upward.

4. Tip the outer casing on its back and pull the volute
from the outer casing. If the volute seems to be stuck,
(due to the O-ring sticking) then use two hands while
holding the outer casing with another person or vise.

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High Pressure Pumps - PKX

Service
9. Inspect the impeller for defects.

10. Remove the spring from the crankshaft. Note: It can

be replaced in either direction.

11. Remove the shim(s) from the crankshaft. Count the

number that is used and replace with the same
amount. Should the impeller or volute be replaced
with new, it will become necessary to re-shim
according the re-shimming procedure noted later in
these instructions.

12. When the shim(s) get stuck inside the impeller.

Carefully pry the shim(s) out with a small screwdriver.
If shim(s) get bent or are flattened beyond use, re
place with new one(s).

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High Pressure Pumps - PKX

Service
17. Use a small screwdriver to pry between the ceramic
seal and the black rubber seal that holds it in place.

18. If the seal seems to be stuck, squirt some liquid soap

on the seal .This will loosen it from the black outer
rubber seal. Using one or two screwdrivers, pry the
seal outward. It may become necessary to remove the
pump backplate when the seal is stuck . See step 22
for removal of backplate.

19. This is what the seal will look like when removed.

20. Make sure never to use the back side of a seal when
re-installing. The back side of the seal will usually
have some colored marks indicating it is the wrong
way.

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High Pressure Pumps - PKX

Service
25. When reassembling the back plate to the engine make
sure the weep hole is facing towards the bottom of
frame. The weep hole is to prevent water from entering
engine should a mechanical seal wear out.

26. Install the pump back plate onto the engine. Install
with one bolt to hold into position.

27. Place a small amount of thread lock sealer on the tip

of the bolts before reinstallation. Note: only use
Allen head bolts and special sealing wahsers.
Washer should fit snug around bolt. Inspect for cracks
in the sealing surfaces of the washers. Replace with
new if needed. Note: Threadlocker Blue or Purplefrom
Permatex is recommended. It is a light, or
medium strength product, and service removable.

28. The four bolts should be tightened snugly by hand.

Tighten diagonally to ensure even installation.

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High Pressure Pumps - PKX

Service
33. Re-install the shim(s) using the same number as was
taken off. If new components such as impeller or
volute was used, it may become necessary to re-shim
with new shims for proper clearance. Check the
procedure listed in a later step on how to perform this
function.

34. Re-install the spring.

35. Hand tighten the impeller onto the crankshaft. Make

sure it is threaded on all they way. If impeller is not
threaded to the full extend, the impeller face could
strike against the inside of the volute.

36. To make sure the impeller is shimmedcorrectly, hold

the volute against the back plate and check the
clearance with a feeler gauge. If the clearance is
larger than 0.0197in. then another shim must be
added.
If there is less than 0.0078 in. between the volute and
impeller, and the unit does not easily turn over with the
rope start, then it is possible that a shim needs to be
removed.

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High Pressure Pumps - PKX

Service
41. Tighten and torque the four bolts to a torque of 22 to
25 ft. lbs.

42. Once the case is torqued down, pull the recoil starter
to check that pump and engine turn over freely. If OK,
then re-fill with prime water. Next check the engine oil
and start the engine. Apply vacuum pressure plate
tester. Reading should be between 20 to 25 lbs of
vacuum at sea level.

43. If it becomes necessary to remove the discharge

nozzle, the following procedure is recommended.
Loosen and remove the 4 bolts that hold the nozzle
housing to the outer casing.

44. Remove the discharge nozzle and inspect the gasket

for tears or breaks. Also check the nozzle casting for
cracks.

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High Pressure Pumps - PKX

Service
49. There is a correct way, and a wrong to install the inlet
gasket. The casting marks must face towards the
engine. If in doubt look at the picture in step 50.

50. This picture shows correct way to install gasket. Make

sure gasket is flat against the outer housing when
reinstalling cover. Align holes and thread the three
bolts into the nozzle and cover.

51. After reinstalling bolts, torque bolts to 4.5 to 6 ft. lbs

Note: The gasket tab must point upward to be
installed correctly.

52. Pull the engine over with rope start to make sure there
is no binding of pump components. Then fill with gas,
oil, and prime water. Start engine and allow to warm
up for a few seconds, then run the throttle at
full speed. Place vacuum tester over intake
opening and check guage reading. The needle should
rise to 20 to 25 inches of vacuum within a few
seconds. If reading is lower, recheck the volute to
impeller clearance as well as possible air leaks around
gasket areas.

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